1. Industrialization Activities in the Americas
Bob Kephart
SRF2011/GDE industrialization
Chicago, July, 2011

2. Introduction
Development of SRF capabilities in U.S. Industry has started in support of future SRF based projects. Examples:
ILC (by far the largest SRF project considered)
JLAB 12 GeV upgrade
FRIB
Project X (would employ ILC cavities)
ERL’s
Etc
U.S. SRF industrialization is primarily funded with generic SRF and ARRA funds (versus ILC funds)
Additional activity is funded by future projects (e.g. above)
In this talk I review the current status and plans for:
North American industrial fabrication of 1.3 GHz elliptical cavities
Industrial fabrication of ILC/PX cryomodule parts
Development of an industrial cavity processing capability
SRF development for PX
There is also additional industrial work on RF power and couplers
July, 2011
GDE meeting Chicago

3. A Possible ILC-SCRF Industrialization Model
ILC Host-Lab
Technical Coordination
(for Lab- Consortium)
Marc Ross Slide
Regional Hub-Lab: A
Regional Hub-Lab:
E, & …
World-wide
Industry responsible for
‘Build-to-Print’ manufacturing by
Cavity/Cryomodule Fabricators
Sub-component Suppliers
Material Venders
Regional Hub-Lab: D
Regional Hub-Lab: B
Comparison with Iter - using the rd phase for tech xfer. Models to be used for construction.
Regional Hub-Lab:
C: responsible for
Hosting System Test and
Gradient Performance
Note 1: -Regional hub-laboratories are responsible for any regional procurement and must be open for world-wide industry participation - Industry may deliver to any region’s laboratory through procurements above
: Coordination link
: Procurement link
July, 2011

4. Strategy
Develop SRF technology in labs, to the extent possible transfer technology to industry for project construction
Motivation for industrial development:
Competition: which should lead to improved performance of SRF components and lower prices for future accelerators ( ILC or Project X)
Availability: Multiple qualified vendors will ensure product availability in case one vendor ceases operations or has other large contracts
Capacity: Promotes increased industrial capacity in preparation for the construction of projects
Concern: Timing for industrialization
Project timescales (PX and ILC) are still uncertain
Once an industrial capability is created it atrophies if not used
Concern: Risk vs. cost in industry  Projects assume risks
Assume: Labs provide costly cryogenic & RF test infrastructure
July, 2011
GDE meeting Chicago

5. Cavity/CM process and Testing
Surface Processing
Cavity Fabrication
Vertical Testing
He Vessel, couplers, tuner
HPR or reprocess
Horizontal Testing
Cold String Assembly
Pass!
Fail!
Pass!
Plan… Develop in labs then transfer technology to industry
July, 2011
GDE meeting Chicago

6. ILC Cavity Industrialization
1.3 GHz cavity procurements support
Cavity R&D towards the ILC S0 goals (FNAL, ANL, JLAB, and Cornell effort)
Construction of CM’s to support ILC S1 & S2 goals
Construction of prototype CM’s for Project X
Development of qualified cavity vendors
All purchases thus far are cavities with the “TESLA” shape
But may consider other shapes in the future
Vendors of course also acquire valuable SRF experience by fabricating cavities of other shapes and frequencies for projects other than ILC
July, 2011
GDE meeting Chicago

7. U.S. Cavity inventory and planned procurements
3 U.S. Vendors
July, 2011
GDE meeting Chicago

8. Advanced Energy Systems 16 nine-cells delivered & 11 tested; + 20 on order
1.3 GHz Tesla single-cell
Electron-beam welding facility
1.3 GHz Tesla nine-cell
1.3 GHz re-entrant nine-cell
July, 2011
GDE meeting Chicago

9. AES cavities Results are very encouraging
Batch 1 (4 cavities) (used EBW from another company)
Delivered, tested (AES004 at 27 MV/M in S1-global CM)
1 cavity (AES002) at 35 MV/M (recovered by 1st dressed EP)
2 other cavities, limited in 20’s by defects (mostly pits),
AES003 repaired by local grinding at KEK and EP at ANL, now 34 MV/M (1st repair by grinding), AES001 ground at KEK, awaits test
Batch 2 (6 cavities) (EBW at AES with new welder)
Delivered, tested
Two cavities with defects (20, 22 MV/M), one recovered to 36 MV/M by CBP
Four cavities exceed 35 MV/M ! (41, 41, 36, 38 MV/M)
Last four cavities processed with 800 C bake…seems to reduce HAZ pits ?
Batch 3 (6 cavities)
Delivered being processed and tested, QC looked good but..
Problems with first light BCP at U.S. vendor… pits… not understood
Batch 4 ( 20 cavities)
Ordered with ARRA funds, Delivery of 10 cavities Fall 2011
July, 2011
GDE meeting Chicago

10. Niowave & Roark collaborate on 1
Niowave & Roark collaborate on 1.3 GHz cavities Roark is working independently on low-beta structures
6 Single-cell cavities deliver Jun 08
-Performed well
6 nine-cell cavities delivered, being processed and tested
10 ARRA funded 9-cell cavities on order
Roark 325 MHz beta=0.22 single-spoke cavity
Delivered Summer 2008
Design = 10 4K
Exceeded 30 2 K
Ordered 10 more for Project X have started to arrive at FNAL
July, 2011
GDE meeting Chicago

11. Niowave- Roark 9-cell ILC Cavities
9-cell performance
2 of 6 nine-cell ILC 1.3 GHz cavities processed & tested so far
One achieved 29 MV/M
The other ~ 17 MV/M
Both quench limited by defects, investigating
Some weld alignment and QC issues to work through
e.g. One HOM notch was off frequency
July, 2011
GDE meeting Chicago

12. PAVAC: Single Cell 1.3 GHz Cavities
6 single cell cavities fabricated
Two different methods of welding
Smart bell - PAV
First weld together half-cells, then add beam tubes
Weld equator from inside
Dumb bell - PAV
First weld each half-cell to a beam tube, then weld together
Two “smart bell” cavities tested so far, both exhibit multi-pacting
Small changes in cell shape from die?
A result of unusual weld technique?
“Dumb bell” cavities will be tested soon
ARRA order for ten 9 cell cavities awaits success on single cells
July, 2011
GDE meeting Chicago

13. ILC PX Not Shown 1 more AES >35 @JLAB New vendor 1st BCP AES
AES replaced damaged end group on A12. CBP then EP
A15 Repaired by CBP 2034
AES002 repaired by dressed EP 33
AES003 repaired at KEK by grinding34
AES006 repaired by CBP to 35
AES005 repaired to 31
ILC PX
Not
Shown
1 more
AES
>35
@JLAB
JLAB & ANL/FNAL facility contributing heavily to ILC gradient program
Pits in EB weld HAZ
New vendor
1st BCP AES

14. U.S. Plan for Cavity Vendor Development
Vendors learn through experience, so in general they will improve their manufacturing processes over time
But, feedback from the laboratories is key to obtaining performance improvements
Careful QA and optical inspection of incoming cavities
Process & test cavities quickly
Relatively small cavity orders allow for feedback between production batched
Larger orders will allow us to better understand costs
Keys to success
Close communication and regular visits
Assistance from experts at FNAL, Cornell, JLab, ANL, DESY, KEK, etc
Learning how to repair cavities !
Stimulus procurements have given cavity vendors a big boost
But concerns about how we sustain this effort in the future
July, 2011
GDE meeting Chicago

15. Industrial Surface Processing
Industrial electro-polish
ARRA funds make it possible for us to fund electro-polish capability in U.S. industry
Competition to perform design study; AES won the bid
AES is in the process of constructing a EP facility
Capable of processing 1300 and 650 MHz elliptical cavities
Benefits from existing clean room, HPR, and chemistry infrastructure funded at AES by Brookhaven National Lab
Eco-friendly surface processing
Funded with ARRA funds
Goal is to produce smooth clean cavity surfaces without using HF and other toxic chemicals
2 companies selected (Faraday bipolar EP, Cabot =CMP) Work in progress
Centrifugal Barrel Polish is under further development at Fermilab
Several 9-cells have achieved ILC gradient after CBP & light EP
Potential to dramatically reduce hazardous acid use
Technique is easily transferable to industry
July, 2011
GDE meeting Chicago

16. U.S. Industrialization of Cryomodules
Strategy on Cryomodule Industrialization
The value added during CM assembly is < 10% the value of the cryomodule.
However the risk is high!
The number we will assemble over the next few years is very small  have no plans to train industry to do assembly of ILC CM
Any training likely to be lost… without follow on work
Not even clear this would make sense for Project X
Strategy is to design cryomodules at labs, order parts from industry, assemble & test at Fermilab
ILC may require a different strategy
Currently testing CM1 (DESY kit) & assembling CM2
July, 2011
GDE meeting Chicago

17. Cryomodule 1 Testing in Progress
-7 cavities are powered
simultaneously from
5 MW klystron using
SLAC RF dist system
-Tuner motor failure
so powered 8 by itself
Preliminary
- 2 with high heat; no FE?
- Calibrations under study
July, 2011
GDE meeting Chicago

18. Dressing cavities for CM2
Cryomodule activities at FNAL
Final Assembly
MP9 Clean Room
CM2 String Assembly
CM1
Move to NML
FNAL S1 global KEK
CM1 installed
Dressing cavities for CM2

19. U.S. Industrialization of Cryomodules
CM3-6 Parts
He Vessels:
Fabricated of Titanium (like XFEL)
20 already procured from Hi-Tech
40 more being procured with ARRA funds from INCODEMA
Tuners
For CM2 and beyond we will use Blade tuners developed by INFN
CM2 and S1-Global: 12 tuners provided by INFN, built in Europe
CM3-CM6: Tuners made by U.S. industry (ARRA)
20 Titanium blade tuners from INCODEMA; 20 from Hi-Tech
Have dressed 18 ILC cavities…
July, 2011
GDE meeting Chicago

20. U.S. Industrialization of Cryomodules
CM3-6 Parts
Couplers (1300 MHz, TTF type)
Vendor is Communications and Power Industries, CPI
SLAC inspects, tests, and conditions couplers for Fermilab
44 couplers ordered and delivered to SLAC
~ half at Fermilab and installed in dressed cavities
Cold mass parts and Vacuum Vessels
4 cryomodules worth of Type IV parts - delivered
Vendor: PHPK Technologies
July, 2011
GDE meeting Chicago

21. New Cryomodule Test Facility (ARRA funded )
New 500 W 1.8 K refrigerator
(under fabrication in industry)
will be located in CMTF bldg
New Electronics building above tunnel extension
New Cryomodule Test Facility
Compressor building
July, 2011
GDE meeting Chicago

22. Project X & SRF industrialization
3 GeV High Intensity Program (2.8 MW)
3 GeV
CW SRF Linac
1 ma H- or Protons
Recycler
Linac: 1 mA x 5 10 Hz
5 pulses per fill
3  8 GeV
Pulsed Linac
(or RCS)
Stripping
foil
8 GeV fast spill (200 KW)
2.2 x Protons / 1.4 sec
LBNE (2 MW)
120 GeV Fast extraction
1.6 x Protons / 1.4 sec
Main Injector
1.4 Sec cycle
Single turn
transfer
At 8 GeV
3-8 GeV linac would be 1300 MHz pulsed retains
synergy with ILC R&D but gradient ~ 25 MV/M
July, 2011
GDE meeting Chicago

23. PX SRF Linac Technology Map
b=0.11
b=0.22
b=0.4
b=0.61
b=0.9
325 MHz
MeV
b=1.0
1.3 GHz
3-8 GeV
ILC
650 MHz
GeV CW
Pulsed
Section
Freq
Energy (MeV)
Cav/mag/CM
Type
SSR0 (G=0.11)
325
2.5-10
18 /18/1
SSR, solenoid
SSR1 (G=0.22)
10-42
20/20/ 2
SSR2 (G=0.4)
42-160
40/20/4
LB (G=0.61)
650
36 /24/6
5-cell elliptical, doublet
HB (G=0.9)
160/40/20
ILC 1.3 (G=1.0)
1300
224 /28 /28
9-cell elliptical, quad
July, 2011
GDE meeting Chicago

24. Things that are Going Well
Cavity vendors are engaged and have orders
ARRA (Stimulus) allowed us to make a start at industrialization
Some U.S. cavity vendors are fabricating world class ILC cavities
Vendors for other cavity and cryomodule parts are established
A matter of finding the right vendor for the type of work required
International vendors have contributed to our progress
e.g. ACCEL/RI cavities have allowed U.S. to validate process and test infrastructure
Have seen
Openness with regards to fabrication techniques (non-disclosure)
Willingness to deal with problems as they arise
Creativity WRT cavity repairs
Urgency to complete projects on time
Intellectual investment
July, 2011
GDE meeting Chicago

25. Things that could use Improvement
Consistency of fabrication / higher yields
EBW associated defects still are not fully understood & under control
Quality Control and Documentation
Dimensional accuracy is less than ideal from some vendors
Sometimes a mistake is made on a first article… understandable… but then not recognized and repeated multiple times..
Key to achieving high yield is controlling the fabrication processes
Need better documented and accessible fabrication records
Communication
Labs need to know when industry is having problems – we can help
Industry needs to provide feedback to Labs regarding our designs and specifications – we need to listen
Still looking for innovation  a better way to do things
Cost of SRF based accelerators is still too high
Value Engineering in industry can help
July, 2011
GDE meeting Chicago

26. Summary
Fermilab is engaged in vendor development with three North American cavity vendors.
Also engaged in industrialization of cryomodule parts, surface processing, RF equipment
Industrialization is being funded by ARRA funds
but one time infusion of funds
U.S. participation in the construction of ILC would require a large scale up of these efforts
Likely that, Project X or other similar projects are the near-term path to U.S. SRF industrialization for a future ILC project
July, 2011
GDE meeting Chicago